Orbital reciprocating saw

Abstract

An orbital reciprocating saw comprising a housing, a motor, a spindle movably supported within said housing and having a front end adapted to support a saw blade, a reciprocating drive assembly, an orbital drive assembly connected to said spindle to selectively drive the saw blade in an orbital path, an orbital adjustment assembly connected to the orbital drive assembly to adjust the orbital path of the saw blade, and an adjustable shoe assembly. The orbital drive assembly includes an eccentric cam member removably supported on the motor drive shaft and engageable with the spindle to cause orbital movement of the saw blade upon rotation of the motor drive shaft. The orbital adjustment assembly selectively disengages the spindle from the cam member during at least a portion of the rotation of the cam member to change the orbital path of the saw blade. The adjustable shoe assembly includes a shoe, a shoe support member pivotally supporting the shoe, a locking member pivotally supported by the housing, and a lever connected to the locking member.

What is claimed is:  
     
       1. A reciprocating saw comprising: 
       a housing;  
       a motor supported by said housing, said motor including a drive shaft rotatable about a drive shaft axis;  
       a spindle movably supported within said housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a drive member connected to said drive shaft and connected to said spindle to reciprocally drive said spindle along a spindle axis relative to said housing upon rotation of said drive shaft;  
       an orbital drive assembly connected to said spindle and operable to selectively drive the saw blade in an orbital path; and  
       an orbital adjustment assembly connected to said orbital drive assembly and operable to change the orbital path of the saw blade, said orbital adjustment assembly including an orbital adjustment member having a cylindrical outer surface defining an axis of rotation substantially parallel to said spindle axis, said orbital adjustment member being rotatable about said axis of rotation to change the orbital path of the saw blade.  
     
     
       2. The reciprocating saw as set forth in claim  1  wherein said orbital drive assembly further includes 
       a support member pivotably supported by said housing, said support member defining a support member axis, said spindle being supported within said support member for reciprocal movement relative to said support member along said support member axis; and  
       a cam follower selectively engageable with said outer surface of said cam member, said cam follower being engageable with said support member, and wherein, during rotation of said drive shaft, engagement of said cam follower with said cam member causes pivoting movement of said support member and orbital movement of the saw blade.  
     
     
       3. The reciprocating saw as set forth in claim  2  wherein said orbital adjustment assembly is operable to selectively disengage said cam follower from said cam member during at least a portion of the rotation of said cam member to change the orbital path of the saw blade. 
     
     
       4. The reciprocating saw as set forth in claim  3  wherein said orbital adjustment member is supported by said housing for movement between a first position, in which a portion of said orbital adjustment member engages a portion of said cam follower during said at least a portion of the rotation of said cam member to disengage said cam follower from said cam member, and a second position. 
     
     
       5. The reciprocating saw as set forth in claim  4  wherein said housing has an upper portion, a lower portion, and opposite side portions, and wherein said orbital adjustment assembly further includes a lever for moving said orbital adjustment member between the first position and the second position, said lever being engageable through said upper portion of said housing. 
     
     
       6. The reciprocating saw as set forth in claim  4  wherein said orbital adjustment member defines therein an opening having a cam surface, wherein, in said first position, a portion of said cam surface engages a portion of said cam follower during said at least a portion of the rotation of said cam member to disengage said cam follower from said cam member. 
     
     
       7. The reciprocating saw as set forth in claim  1  wherein said spindle reciprocates along a spindle axis, and wherein said axis of rotation of said orbital adjustment member is substantially parallel to said spindle axis. 
     
     
       8. A reciprocating saw comprising: 
       a housing;  
       a motor supported by said housing, said motor including a drive shaft rotatable about a drive shaft axis;  
       a spindle movably supported within said housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a wobble plate mounted on said drive shaft and connected to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       an orbital drive assembly connected to said spindle and operable to selectively drive the saw blade in an orbital path, said orbital drive assembly including a cam member supported on said drive shaft, said cam member having an eccentric outer surface relative to said drive shaft axis, said cam member being engageable with said spindle to cause orbital movement of the saw blade upon rotation of said drive shaft; and  
       an orbital adjustment assembly connected to said orbital drive assembly and operable to adjust the orbital path of the saw blade;  
       wherein said orbital drive assembly further includes  
       a support member pivotably supported by said housing, said support member defining a support member axis, said spindle being supported within said support member for reciprocal movement relative to said support member along said support member axis, and  
       a cam follower selectively engageable with said outer surface of said cam member, said cam follower being engageable with said support member, and wherein, during rotation of said drive shaft, engagement of said cam follower with said cam member causes pivoting movement of said support member and orbital movement of the saw blade;  
       wherein said orbital adjustment assembly is operable to selectively disengage said cam follower from said cam member during at least a portion of the rotation of said cam member to change the orbital path of the saw blade;  
       wherein said orbital adjustment assembly includes an orbital adjustment member supported by said housing for movement between a first position, in which a portion of said orbital adjustment member engages a portion of said cam follower during said at least a portion of the rotation of said cam member to disengage said cam follower from said cam member, and a second position;  
       wherein said orbital adjustment member defines therein an opening having a cam surface, wherein, in said first position, a portion of said cam surface engages a portion of said cam follower during said at least a portion of the rotation of said cam member to disengage said cam follower from said cam member;  
       wherein said orbital adjustment member has a cylindrical outer surface defining an axis of rotation; and wherein said orbital adjustment member is rotatable about said axis between said first position and said second position.  
     
     
       9. The reciprocating saw as set forth in claim  8  wherein said spindle reciprocates along a spindle axis, and wherein said axis of rotation of said orbital adjustment member is substantially parallel to said spindle axis. 
     
     
       10. A drive assembly for a reciprocating saw including a housing and a motor supported by the housing, the motor including a drive shaft rotatable about a drive shaft axis, said drive assembly comprising: 
       a spindle movably supported within the housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke, said spindle defining a bore;  
       a wobble plate mounted on the drive shaft and connected to said spindle to reciprocally drive said spindle relative to the housing upon rotation of the drive shaft, said wobble plate including a drive arm having an end receivable in said bore; and  
       a wear compensating member positioned in said bore and engageable with said end of said drive arm, wherein said wear compensating member is a spring.  
     
     
       11. The reciprocating saw as set forth in claim  10  wherein said saw further comprises: 
       a counterweight movably supported within said housing; and  
       a second wobble plate mounted on said drive shaft and connected to said counterweight to reciprocally drive said counterweight relative to said housing upon rotation of said drive shaft to counterbalance a force created by movement of said spindle.  
     
     
       12. The reciprocating saw as set forth in claim  11  wherein second wobble plate includes a second drive arm having an end, wherein said counterweight includes a bore for receiving said end of said second drive arm, and wherein said counterweight includes a second wear compensating member positioned in said bore and engageable with said end of said second drive arm. 
     
     
       13. The reciprocating saw as set forth in claim  12  wherein said second wear compensating member is a spring. 
     
     
       14. A drive assembly for a reciprocating saw including a housing and a motor supported by the housing, the motor including a drive shaft rotatable about a drive shaft axis, said drive assembly comprising: 
       a spindle movably supported within the housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a reciprocating drive assembly including a drive arm operably connected to the drive shaft and to said spindle to reciprocally drive said spindle relative to the housing upon rotation of the drive shaft; and  
       a wear compensating member positioned between said spindle and said drive arm;  
       wherein said wear compensating member is a spring.  
     
     
       15. The reciprocating saw as set forth in claim  14  wherein said saw further comprises a counterweight movably supported within said housing, and wherein said reciprocating drive assembly further includes a second drive arm operably connected to said drive shaft and to said counterweight to reciprocally drive said counterweight relative to said housing upon rotation of said drive shaft to counterbalance a force created by movement of said spindle. 
     
     
       16. The reciprocating saw as set forth in claim  15  wherein said saw further comprises a second wear compensating member positioned between said counterweight and said second drive arm. 
     
     
       17. The reciprocating saw as set forth in claim  16  wherein said second wear compensating member is a spring. 
     
     
       18. A reciprocating saw comprising: 
       a housing;  
       a motor supported by said housing, said motor including a drive shaft rotatable about a drive shaft axis;  
       a spindle movably supported within said housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a reciprocating drive assembly operably connected to said drive shaft and to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       an orbital drive assembly connected to said spindle and operable to selectively drive the saw blade in an orbital path, said orbital drive assembly including a cam member supported on said drive shaft, said cam member having an eccentric outer surface relative to said drive shaft axis, said cam member being engageable with said spindle to cause orbital movement of the saw blade upon rotation of said drive shaft; and  
       an orbital adjustment assembly connected to said orbital drive assembly and operable to adjust the orbital path of the saw blade;  
       wherein said orbital drive assembly further includes  
       a support member pivotably supported by said housing, said support member defining a support member axis, said spindle being supported within said support member for reciprocal movement relative to said support member along said support member axis, and  
       a cam follower selectively engageable with said outer surface of said cam member, said cam follower being engageable with said support member, wherein, during rotation of said drive shaft, engagement of said cam follower with said cam member causes pivoting movement of said support member and orbital movement of the saw blade;  
       wherein said orbital adjustment assembly is operable to selectively disengage said cam follower from said cam member during only a portion of a rotation of said cam member to change the orbital path of the saw blade;  
       wherein said reciprocating drive assembly includes a wobble plate mounted on said drive shaft and connected to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       wherein said saw further comprises a counterweight movably supported within said housing, and wherein said reciprocating drive assembly further includes a second wobble plate mounted on said drive shaft and connected to said counterweight to reciprocally drive said counterweight relative to said housing upon rotation of said drive shaft to counterbalance a force created by movement of said spindle.  
     
     
       19. The reciprocating saw as set forth in claim  18  wherein second wobble plate includes a second drive arm having an end, wherein said counterweight includes a bore for receiving said end of said second drive arm, and wherein said counterweight includes a wear compensating member positioned in said bore and engageable with said end of said second drive arm. 
     
     
       20. The reciprocating saw as set forth in claim  19  wherein said wear compensating member is a spring. 
     
     
       21. A reciprocating saw comprising: 
       a housing;  
       a motor supported by said housing, said motor including a drive shaft rotatable about a drive shaft axis;  
       a spindle movably supported within said housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a reciprocating drive assembly operably connected to said drive shaft and to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       an orbital drive assembly connected to said spindle and operable to selectively drive the saw blade in an orbital path, said orbital drive assembly including a cam member supported on said drive shaft, said cam member having an eccentric outer surface relative to said drive shaft axis, said cam member being engageable with said spindle to cause orbital movement of the saw blade upon rotation of said drive shaft; and  
       an orbital adjustment assembly connected to said orbital drive assembly and operable to adjust the orbital path of the saw blade;  
       wherein said orbital drive assembly further includes  
       a support member pivotably supported by said housing, said support member defining a support member axis, said spindle being supported within said support member for reciprocal movement relative to said support member along said support member axis, and  
       a cam follower selectively engageable with said outer surface of said cam member, said cam follower being engageable with said support member, wherein, during rotation of said drive shaft, engagement of said cam follower with said cam member causes pivoting movement of said support member and orbital movement of the saw blade;  
       wherein said orbital adjustment assembly is operable to selectively disengage said cam follower from said cam member during only a portion of a rotation of said cam member to change the orbital path of the saw blade;  
       wherein said reciprocating drive assembly includes a wobble plate mounted on said drive shaft and connected to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       wherein said saw further comprises a counterweight movably supported within said housing, wherein said reciprocating drive assembly further includes a second wobble plate mounted on said drive shaft and connected to said counterweight to reciprocally drive said counterweight relative to said housing upon rotation of said drive shaft to counterbalance a force created by movement of said spindle;  
       wherein second wobble plate includes a second drive arm having an end, wherein said counterweight includes a bore for receiving said end of said second drive arm, and wherein said counterweight includes a second wear compensating member positioned in said bore and engageable with said end of said second drive arm.  
     
     
       22. The reciprocating saw as set forth in claim  21  wherein said second wear compensating member is a spring. 
     
     
       23. A reciprocating saw comprising: 
       a housing;  
       a motor supported by said housing, said motor including a drive shaft rotatable about a drive shaft axis;  
       a spindle movably supported within said housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a reciprocating drive assembly operably connected to said drive shaft and to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       an orbital drive assembly connected to said spindle and operable to selectively drive the saw blade in an orbital path, said orbital drive assembly including a cam member supported on said drive shaft, said cam member having an eccentric outer surface relative to said drive shaft axis, said cam member being engageable with said spindle to cause orbital movement of the saw blade upon rotation of said drive shaft; and  
       an orbital adjustment assembly connected to said orbital drive assembly and operable to adjust the orbital path of the saw blade;  
       wherein said orbital drive assembly further includes  
       a support member pivotably supported by said housing, said support member defining a support member axis, said spindle being supported within said support member for reciprocal movement relative to said support member along said support member axis, and  
       a cam follower selectively engageable with said outer surface of said cam member, said cam follower being engageable with said support member, wherein, during rotation of said drive shaft, engagement of said cam follower with said cam member causes pivoting movement of said support member and orbital movement of the saw blade;  
       wherein said orbital adjustment assembly is operable to selectively disengage said cam follower from said cam member during only a portion of a rotation of said cam member to change the orbital path of the saw blade;  
       wherein said orbital adjustment assembly includes an orbital adjustment member supported by said housing for movement between a first position, in which a portion of said orbital adjustment member engages a portion of said cam follower during said portion of the rotation of said cam member to disengage said cam follower from said cam member during said portion of the rotation of said cam member, and a second position;  
       wherein said housing has an upper portion, a lower portion, and opposite side portions, wherein said orbital adjustment assembly further includes a lever for moving said orbital adjustment member between the first position and the second position, said lever being engageable through said upper portion of said housing;  
       wherein said orbital adjustment member has a cylindrical outer surface defining an axis of rotation, and wherein said lever is operable to pivot said orbital adjustment member about said axis between said first position and said second position.  
     
     
       24. A reciprocating saw comprising: 
       a housing;  
       a motor supported by said housing, said motor including a drive shaft rotatable about a drive shaft axis;  
       a spindle movably supported within said housing, said spindle having a front end adapted to support a saw blade through a cutting stroke and a return stroke;  
       a reciprocating drive assembly operably connected to said drive shaft and to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       an orbital drive assembly connected to said spindle and operable to selectively drive the saw blade in an orbital path, said orbital drive assembly including a cam member supported on said drive shaft, said cam member having an eccentric outer surface relative to said drive shaft axis, said cam member being engageable with said spindle to cause orbital movement of the saw blade upon rotation of said drive shaft; and  
       an orbital adjustment assembly connected to said orbital drive assembly and operable to adjust the orbital path of the saw blade;  
       wherein said orbital drive assembly further includes  
       a support member pivotably supported by said housing, said support member defining a support member axis, said spindle being supported within said support member for reciprocal movement relative to said support member along said support member axis, and  
       a cam follower selectively engageable with said outer surface of said cam member, said cam follower being engageable with said support member, wherein, during rotation of said drive shaft, engagement of said cam follower with said cam member causes pivoting movement of said support member and orbital movement of the saw blade;  
       wherein said orbital adjustment assembly is operable to selectively disengage said cam follower from said cam member during only a portion of a rotation of said cam member to change the orbital path of the saw blade;  
       wherein said reciprocating drive assembly includes a wobble plate mounted on said drive shaft and connected to said spindle to reciprocally drive said spindle relative to said housing upon rotation of said drive shaft;  
       wherein said wobble plate includes a drive arm having an end, wherein said spindle defines a bore for receiving said end of said drive arm, wherein said spindle includes a wear compensating member positioned in said bore and engageable with said end of said drive arm; and  
       wherein said wear compensating member is a spring.